How to Cut Parallel Sides on Aluminum
- 1). Lay your aluminum stock on a flat, hard surface. Determine the width of the lines to be cut on the stock. If you need to cut sheet aluminum, use a steel ruler and a fine-tip felt pen to measure from the end of the stock. Make small dots with the pen at each end of the stock. Use the pen to join the dots with a straight line, for however many cuts you need. Place the aluminum stock over the top of a table saw.
- 2). Move the stock next to the blade, and adjust the blade up so it protrudes about 1/4-inch above the height of the stock. Use a wax stick to rub a thick line over your first pen line, where you intend to cut. Don a pair of thick gauntlet gloves and safety goggles. Push the end of the aluminum stock up flush with the fence guide on the table saw.
- 3). Turn the adjusting wheel on the fence guide so the pen mark -- the first cutting line -- aligns dead center with the tip of the saw blade. Position a pushing stick with one hand at the far side of the aluminum stock. Turn the table saw on with the other hand. Wait for the blade to reach maximum revolutions.
- 4). Begin to shove the pushing stick with one hand to move the stock into the blade, while pushing the stock inward toward the fence with the other hand. Push slowly; do not allow the aluminum stock to chatter. Do not twist, or stop the forward motion of the stock over the table surface.
- 5). Step to the side of the table once the blade has reached about an inch from cutting the end of the stock, keeping both hands on the stock, with your elbows bowed outward. Turn the machine off when the cut has been made. Dust the aluminum shavings off the table saw with a whisk broom. Remove the cut piece. Readjust the fence for your next cut, and wax your next cut line. Repeat the procedure as you did for the first cut.
Source...